Note: Descriptions are shown in the official language in which they were submitted.
CA 02886984 2015-03-31
WO 2014/071056 PCT/US2013/067845
GRAPHICAL EVALUATOR FOR TUBULAR MAKEUP
CROSS-REFERENCE TO RELATED APPLICATIONS
[0ool] This application claims benefit of United States provisional patent
application
serial number 61/720,426, filed October 31, 2012, which is herein incorporated
by
reference.
BACKGROUND OF THE DISCLOSURE
Field of the Disclosure
[0002] The present disclosure generally relates to a method for makeup
evaluation
visualization to automatically detect acceptable or unacceptable connections
during
tubular makeup.
Description of the Related Art
[0003] In wellbore construction and completion operations, a wellbore is
formed to
access hydrocarbon-bearing formations (e.g., crude oil and/or natural gas) by
the use
of drilling. Drilling is accomplished by utilizing a drill bit that is mounted
on the end of
a drill string. To drill within the wellbore to a predetermined depth, the
drill string is
often rotated by a top drive or rotary table on a surface platform or rig, or
by a
downhole motor mounted towards the lower end of the drill string. After
drilling to a
predetermined depth, the drill string and drill bit are removed and a string
of casing is
lowered into the wellbore. An annulus is thus formed between the casing string
and
the formation. The casing string is temporarily hung from the surface of the
well. A
cementing operation is then conducted in order to fill the annulus with
cement. The
casing string is cemented into the wellbore by circulating cement into the
annulus
defined between the outer wall of the casing and the borehole. The combination
of
cement and casing strengthens the wellbore and facilitates the isolation of
certain
areas of the formation behind the casing for the production of hydrocarbons.
[0004] A drilling rig is constructed on the earth's surface or floated
on water to
facilitate the insertion and removal of tubular strings (e.g., drill pipe,
casing, sucker
rod, riser, or production tubing) into a wellbore. The drilling rig includes a
platform
and power tools, such as an elevator and slips, to engage, assemble, and lower
the
tubulars into the wellbore. The elevator is suspended above the platform by a
draw
works that can raise or lower the elevator in relation to the floor of the
rig. The slips
CA 02886984 2015-03-31
WO 2014/071056 PCT/US2013/067845
are mounted in the platform floor. The elevator and slips are each capable of
engaging and releasing a tubular and are designed to work in tandem.
Generally, the
slips hold a tubular or tubular string that extends into the wellbore from the
platform.
The elevator engages a tubular joint and aligns it over the tubular string
being held by
the slips. One or more power drives, e.g. a power tong and a spinner, are then
used
to thread the joint and the string together. Once the tubulars are joined, the
slips
disengage the tubular string and the elevator lowers the tubular string
through the
slips until the elevator and slips are at a predetermined distance from each
other.
The slips then reengage the tubular string and the elevator disengages the
string and
repeats the process. This sequence applies to assembling tubulars for the
purpose of
drilling, deploying casing, or deploying other components into the wellbore.
The
sequence is reversed to disassemble the tubular string.
SUMMARY OF THE DISCLOSURE
[0005] The present disclosure generally relates to a method for makeup
evaluation
visualization to automatically detect acceptable or unacceptable connections
during
tubular makeup. In one embodiment, a method of connecting a first threaded
tubular
to a second threaded tubular includes: engaging threads of the tubulars; and
rotating
the first tubular relative to the second tubular, thereby making up the
threaded
connection. The method further includes, during makeup of the threaded
connection:
measuring torque applied to the connection; measuring turns of the first
tubular; and
detecting a shoulder position. The method further includes: displaying the
measured
torque and turns; overlaying a reference curve onto the display; evaluating
the
threaded connection by comparing the measured torque and turns to the
reference
curve; and graphically displaying the evaluation.
[0006] In another embodiment, a tubular makeup system includes: a power
drive
operable rotate a first threaded tubular relative to a second threaded
tubular; a torque
cell; a turns counter; and a programmable logic controller (PLC) operably
connected
to the power drive and in communication with the torque cell and turns
counter. The
PLC is configured to control an operation including: engaging threads of the
tubulars;
and rotating the first tubular relative to the second tubular, thereby making
up the
threaded connection. The operation further includes, during makeup of the
threaded
connection: measuring torque applied to the connection; measuring turns of the
first
2
CA 02886984 2015-03-31
WO 2014/071056 PCT/US2013/067845
tubular; and detecting a shoulder position. The operation further includes:
displaying
the measured torque and turns; overlaying a reference curve onto the display;
evaluating the threaded connection by comparing the measured torque and turns
to
the reference curve; and graphically displaying the evaluation.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] So that the manner in which the above recited features of the
present
disclosure can be understood in detail, a more particular description of the
disclosure,
briefly summarized above, may be had by reference to embodiments, some of
which
are illustrated in the appended drawings. It is to be noted, however, that the
appended drawings illustrate only typical embodiments of this disclosure and
are
therefore not to be considered limiting of its scope, for the disclosure may
admit to
other equally effective embodiments.
[0oos] Figure 1A is a partial cross section view of a connection between
threaded
premium grade tubulars. Figure 1B is a partial cross section view of a
connection
between threaded premium grade tubulars in a seal position formed by
engagement
between sealing surfaces. Figure 10 is a partial cross section view of a
connection
between threaded premium grade tubulars in a shoulder position formed by
engagement between shoulder surfaces.
[0009] Figure 2A illustrates an ideal torque-turns curve for the premium
connection. Figure 2B illustrates an ideal torque gradient-turns curve for the
premium
connection.
[0olo] Figure 3A is a perspective view of a tong assembly in an upper
position.
Figure 3B is a block diagram illustrating a tubular makeup system, according
to one
embodiment of the present disclosure.
[0011] Figures 4A and 4B illustrate operation of a graphical evaluator of
the tubular
makeup system for an acceptable connection.
[0012] Figures 5A and 5B illustrate operation of the graphical evaluator
for an
unacceptable connection due to violation of a final torque criterion.
[0013] Figures 6A and 6B illustrate operation of the graphical evaluator
for an
unacceptable connection due to violation of a delta turn criterion.
3
CA 02886984 2015-03-31
WO 2014/071056 PCT/US2013/067845
[0014] Figures 7A and 7B illustrate operation of the graphical evaluator
for an
unacceptable connection due to violation of a reference curve criterion.
[0015] Figures 8A and 8B illustrate operation of the graphical evaluator
for an
unacceptable connection due to violation of a delta gradient criterion.
DETAILED DESCRIPTION
[0016] Figure 1A illustrates a connection 1 between premium grade
tubulars 2, 4.
The tubulars 2, 4 may be any oil country tubular good, such as production
tubing,
casing, liner, or drill pipe. The connection 1 may include a first tubular 2
joined to a
second tubular 4 through a tubular coupling 6. Each of the tubulars 2, 4 and
the
coupling 6 may be made from a metal or alloy, such as plain carbon steel, low
alloy
steel, high strength low alloy steel, stainless steel, or a nickel based
alloy. The end of
each tubular 2, 4 may have a tapered externally-threaded surface 8 (aka a pin)
which
co-operates with a correspondingly tapered internally-threaded surface (aka
box) 10
on the coupling 6. Each tubular 2, 4 may be provided with a torque shoulder 12
which
co-operates with a corresponding torque shoulder 14 on the coupling 6. At a
terminal
end of each tubular 2, 4, there may be defined an annular sealing area 16
which is
engageable with a co-operating annular sealing area 18 defined between the
tapered
portions 10, 14 of the coupling 6. Alternatively, the sealing areas 16,18 may
be
located at other positions in the connection 1 than adjacent the shoulders
12,14.
[0017] During makeup, the box 10 is engaged with the pin 8 and then screwed
onto the pin by relative rotation therewith. During continued rotation, the
annular
sealing areas 16, 18 contact one another, as shown in Figure 1B. This initial
contact
is referred to as the "seal position". As the coupling 6 is further rotated,
the co-
operating tapered torque shoulders 12, 14 contact and bear against one another
at a
machine detectable stage referred to as a "shoulder position", as shown in
Figure 10.
The increasing pressure interface between the tapered torque shoulders 12, 14
cause
the seals 16, 18 to be forced into a tighter metal-to-metal sealing engagement
with
each other causing deformation of the seals 16 and eventually forming a fluid-
tight
seal.
[0018] Figure 2A illustrates an ideal torque-turns curve 50 for the premium
connection. Figure 2B illustrates an ideal torque gradient-turns curve 50a for
the
4
CA 02886984 2015-03-31
WO 2014/071056 PCT/US2013/067845
premium connection.
During makeup of the tubulars 2, 4, torque and turns
measurements may be recorded and the curves 50, 50a displayed for evaluation
by a
technician. Shortly after the coupling 6 engages the tubular 4 and torque is
applied,
the measured torque increases linearly as illustrated by curve portion 52. As
a result,
corresponding curve portion 52a of the differential curve 50a is flat at some
positive
value.
[0019]
During continued rotation, the annular sealing areas 16, 18 contact one
another causing a slight change (specifically, an increase) in the torque
rate, as
illustrated by point 54. Thus, point 54 corresponds to the seal position shown
in
Figure 1 B and is plotted as the first step 54a of the differential curve 50a.
The torque
rate then again stabilizes resulting in the linear curve portion 56 and the
plateau 56a.
In practice, the seal condition (point 54) may be too slight to be detectable.
However,
in a properly behaved makeup, a discernable/detectable change in the torque
rate
occurs when the shoulder position is achieved (corresponding to Figure 10), as
represented by point 58 and step 58a. The torque rate then again increases
linearly
as illustrated by curve portion 60 and the plateau 60a until makeup of the
connection
is terminated at final torque 62.
[0020]
Figure 3A is a perspective view of a power drive, such as tong assembly
100, in an upper position. A group 140g of clamps has been removed for
illustrative
purposes. The tong assembly 100 may include a power tong 102 and a back-up
tong
104 located on a drilling rig 106 coaxially with a drilling center 108 of the
drilling rig
106. The assembly 100 may be coupled in a vertically displaceable manner to
one or
more guide columns 110 (two shown) arranged diametrically opposite each other
relative to the drilling centre 108. The guide columns 110 may be connected to
a
chassis 112 which by wheels 114 and hydraulic motors (not shown) may be
displaced
horizontally on rails 116 connected to the drilling rig 106. In the operative
position, the
assembly 100 may be located immediately above the slips 118 of the drilling
rig 106.
[0021]
The power tong 102 may include a power tong housing provided with a
through aperture that corresponds to the guide columns 110, and an undivided
drive
ring connected via a bearing ring (not shown). The bearing ring may have a
toothed
ring (not shown) in mesh with cogwheels (not shown) on one or more hydraulic
motors (not shown), such as two. One of the motors may be a spinner motor
(high
speed, low torque) and the other motor may be one or more torque motors (high
5
CA 02886984 2015-03-31
WO 2014/071056 PCT/US2013/067845
torque, low speed). The toothed ring may be coupled to the drive ring by screw-
bolt-
joints (not shown). The hydraulic motors may be arranged to rotate the drive
ring
about the drilling centre 108. The two hydraulic motors may be disposed on
diametrically opposite sides of the drive ring. A cover may be provided to
cover the
power tong housing.
[0022] In the drive ring and co-rotating with this may be two crescent-
shaped
groups 140g (only one shown) of clamps. Each group 140g of clamps may be
provided with one or more, such as three, clamps distributed around the
drilling center
108. Each clamp may include a cylinder block provided with one or more, such
as
three, cylinder bores arranged in a vertical row. In each cylinder bore may be
a
corresponding longitudinally displaceable piston that seals against the
cylinder bore
by a piston gasket. A rear gasket may prevent pressurized fluid from flowing
out
between the piston and the cylinder bore at the rear end of the piston.
[0023] The pistons may be fastened to the housing of the group 140g of
clamps by
respective screw-bolt-joints. On the part of the cylinder block facing the
drilling center
108 there may be provided a gripper. The gripper may be connected to the
cylinder
block by fastening, such as with dovetail grooves or screw-bolt-joints (not
shown).
Surrounding the drive ring there may be provided a swivel ring that seals by
swivel
gaskets, the swivel ring may be stationary relative to the power tong housing.
The
swivel ring may have a first passage that communicates with the plus side of
the
pistons via a first fluid connection, a second passage that communicates with
the
minus side of the pistons via a second fluid connection, and a further
passage. The
cylinder and the piston may thereby be double acting. The swivel ring, swivel
gaskets
and drive ring may together form a swivel coupling.
[0024] The backup tong 104 may also include the clamp groups. The back-up
tong 104 may further include a back-up tong housing with guides 176 that
correspond
with the guide columns 110, and a retainer ring for two groups of clamps. At
the
guides 176 there may be cogwheels that mesh with respective pitch racks of the
guide columns 110. Separate hydraulic motors may drive the cogwheels via
gears. A
pair of hydraulic cylinders may be arranged to adjust the vertical distance
between the
power tong 102 and the back-up tong 104.
6
CA 02886984 2015-03-31
WO 2014/071056 PCT/US2013/067845
[0025] In operation, when the tubular joint 2 is to be added to tubular
string 20
(already including tubular joint 4), the assembly 100 may be displaced
vertically along
the guide columns 110 by the hydraulic motors, the gears, the cogwheels and
the
pitch racks until the back-up tong 104 corresponds with the pin 8 of the
tubular string
20. The box 10 of the coupling 6 may have been madeup to the pin 8 of the
joint 2
offsite (aka bucking operation) before the tubulars 2, 4 are transported to
the rig.
Alternatively the coupling 6 may be bucked on the joint 4 instead of the joint
2.
Alternatively, the coupling 6 may be welded to one of the tubulars 2, 4
instead of
being bucked on.
[0026] The vertical distance between the back-up tong 104 and the power
tong
102 may be adjusted so as to make the grippers correspond with the coupling 6.
The
clamps may be moved up to the coupling 6 by pressurized fluid flowing to the
first
passage in the swivel ring and on through the first fluid connection to the
plus side of
the pistons. The excess fluid on the minus side of the pistons may flow via
the second
fluid connection and the second passage back to a hydraulic power unit (not
shown).
[0027] The grippers may then grip their respective pin or box while the
hydraulic
motors rotate the drive ring and the groups 140g of clamps about the drilling
center
108, while at the same time constant pressure may be applied through the
swivel ring
to the plus side of the pistons. The power tong 102 may be displaced down
towards
the back-up tong 104 while the screwing takes place. After the desired torque
has
been achieved, the rotation of the drive ring may be stopped. The clamps may
be
retracted from the tubular string 20 by pressurized fluid being delivered to
the minus
side of the pistons via the swivel ring. The assembly 100 may be released from
the
tubular string 20 and moved to its lower position.
[0on] When a joint 2 is to be removed from the tubular string 20, the
operation is
performed in a similar manner to that described above. When tools or other
objects of
a larger outer diameter than the tubular string 20 are to be displaced through
the
assembly 100, the grippers may easily be removed from their respective clamps,
or
alternatively the groups 140g of clamps can be lifted out of the drive ring.
[0029] Alternatively, other types of tong assemblies may be used instead of
the
tong assembly 100.
7
CA 02886984 2015-03-31
WO 2014/071056 PCT/US2013/067845
[0030] Figure 3B is a block diagram illustrating a tubular makeup system
200,
according to one embodiment of the present disclosure. The tubular makeup
system
200 may include the tong assembly 100, a tong remote unit (TRU) 204, a turns
counter 208, a torque cell 212, and the control system 206. The control system
206
may communicate with the TRU 204 via an interface. Depending on sophistication
of
the TRU 204, the interface may be analog or digital. Alternatively, the
control system
206 may also serve as the TRU.
[0031] A programmable logic controller (PLC) 216 of the control system
206 may
monitor the turns count signals 210 and torque signals 214 from the respective
sensors 208, 212 and compare the measured values of these signals with
predetermined values 223-230. The predetermined values 223-230 may be input by
an technician for a particular connection. The predetermined values 223-230
may be
input to the PLC 216 via an input device 218, such as a keypad.
[0032] Illustrative predetermined values 223-230 which may be input, by
an
technician or otherwise, include minimum and maximum delta gradient values
223, a
shoulder threshold gradient 224, a dump torque value 226, minimum and maximum
delta turns values 228, minimum and maximum torque values 230, and reference
curve data 231. The minimum and maximum torque values 230 may include a set
for
the shoulder position and a set for the final position. The torque values 230
may be
derived theoretically, such as by finite element analysis, or empirically,
such as by
laboratory testing and/or analysis of historical data for a particular
connection. The
dump torque value 226 may simply be an average of the final minimum and
maximum
torque values 230. During makeup of the connection 1, various output may be
observed by an technician on output device, such as a video monitor, which may
be
one of a plurality of output devices 220. A technician may observe the various
predefined values which have been input for a particular connection. Further,
the
technician may observe graphical information such as the torque rate curve 50
and
the torque rate differential curve 50a. The plurality of output devices 220
may also
include a printer such as a strip chart recorder or a digital printer, or a
plotter, such as
an x-y plotter, to provide a hard copy output. The plurality of output devices
220 may
further include an alarm, such as a horn or other audio equipment, to alert
the
technician of significant events occurring during makeup, such as the shoulder
position, termination, and/or a violation of a criterion.
8
CA 02886984 2015-03-31
WO 2014/071056 PCT/US2013/067845
[0033] Upon the occurrence of a predefined event(s), the PLC 216 may
output a
dump signal 222 to the TRU 204 to automatically shut down or reduce the torque
exerted by the tong assembly 100. For example, dump signal 222 may be issued
in
response to the measured torque value reaching the dump torque 226 and/or a
bad
connection.
[0034] The comparison of measured turn count values and torque values
with
respect to predetermined values is performed by one or more functional units
of the
PLC 216. The functional units may generally be implemented as hardware,
software
or a combination thereof. The functional units may include one or more of a
torque-
turns plotter algorithm 232, a process monitor 234, a torque gradient
calculator 236, a
smoothing algorithm 238, a sampler 240, a database 242 of reference curves, a
connection evaluator 252, and a target detector 254. The process monitor 234
may
include one or more of a thread engagement detection algorithm 244, a seal
detection
algorithm 246, a shoulder detection algorithm 248, and a graphical evaluator
algorithm 250. Alternatively, the functional units may be performed by a
single unit.
As such, the functional units may be considered logical representations,
rather than
well-defined and individually distinguishable components of software or
hardware.
[0035] In operation, one of the threaded members (e.g., tubular 2 and
coupling 6)
is rotated by the power tong 102 while the other tubular 4 is held by the
backup tong
104. The applied torque and rotation are measured at regular intervals
throughout
the makeup. The frequency with which torque and rotation are measured may be
specified by the sampler 240. The sampler 240 may be configurable, so that an
technician may input a desired sampling frequency. The torque and rotation
values
may be stored as a paired set in a buffer area of memory. Further, the rate of
change
of torque with respect to rotation (hereinafter "torque gradient") may be
calculated for
each paired set of measurements by the torque gradient calculator 236. The
smoothing algorithm 238 may operate to smooth the torque-turns curve 50 and/or
torque gradient curve 50a (e.g., by way of a running average). These values
(torque,
rotation, and torque gradient) may then be plotted by the plotter 232 for
display on the
output device 220.
[0036] The values (torque, rotation, and torque gradient) may then be
compared
by the connection evaluator 252, either continuously or at selected events,
with
predetermined values, such as the values 223-230. Based on the comparison of
the
9
CA 02886984 2015-03-31
WO 2014/071056 PCT/US2013/067845
measured and/or calculated values with the predefined values 223-230, the
process
monitor 234 may determine the occurrence of various events and the connection
evaluator 252 may determine whether to continue rotation or abort the makeup.
The
thread engagement detection algorithm 244 may monitor for thread engagement of
the pin 8 and box 10. Upon detection of thread engagement a first marker is
stored.
The marker may be quantified, for example, by time, rotation, torque, the
torque
gradient, or a combination of any such quantifications. During continued
rotation, the
seal detection algorithm 246 monitors for the seal condition.
This may be
accomplished by comparing the calculated torque gradient with a predetermined
threshold seal condition value. A second marker indicating the seal condition
may be
stored if/when the seal condition is detected. At this point, the torque value
at the
seal condition may be evaluated by the connection evaluator 252.
[0037]
For example, a determination may be made as to whether the turns value
and/or torque value are within specified limits.
The specified limits may be
predetermined, or based off of a value measured during makeup. If the
connection
evaluator 252 determines a bad connection, rotation may be terminated.
Otherwise,
rotation continues and the shoulder detection algorithm 248 monitors for the
shoulder
position. This may be accomplished by comparing the calculated torque gradient
with
the shoulder threshold gradient 224. When the shoulder position is detected, a
third
marker indicating the shoulder position is stored. The connection evaluator
252 may
then determine whether the torque value at the shoulder position is acceptable
by
comparing to the respective input torque values 230.
[0038]
Upon continuing rotation, the target detector 254 compares the measured
torque to the dump torque value 226. Once the dump torque value 226 is
reached,
rotation may be terminated by sending the dump signal 222. Alternatively, the
dump
signal 222 may be issued slightly before the dump torque 226 is reached to
account
for system inertia. Once the connection is complete, the connection evaluator
252
may calculate a delta turns value based on the difference between the final
turns
value and the turns value at the shoulder condition. The connection evaluator
252
may compare the delta turns value with the input delta turns values 228.
Similarly,
the connection evaluator may compare the final torque value to the respective
input
torque values 230. The connection evaluator 252 may calculate a delta torque
value
based on the difference between the final torque value and the torque value at
the
CA 02886984 2015-03-31
WO 2014/071056 PCT/US2013/067845
shoulder condition. The connection evaluator 252 may calculate a delta
gradient
value using delta torque and delta turns values and compare it with the
respective
input values 223. If either criteria is not met, then the connection evaluator
252 may
indicate a bad connection.
[0039] Alternatively, a delta turns value may be entered instead of the
dump
torque 226. The target detector 254 may then calculate a target turns value
using the
shoulder turns and the delta turns value (target turns equals shoulder turns
plus delta
turns).
[0040] Figures 4A and 4B illustrate operation of the graphical evaluator
250 of the
tubular makeup system 200 for an acceptable connection 1. For the sake of
clarity,
the curves have been simplified relative to actual field data. The graphical
evaluator
250 may be operable to overlay one or more (two shown) reference curves onto
the
torque-turns curve during makeup of the threaded connection. The graphical
evaluator may retrieve the reference curves from the database 242. The
database
242 may include torque-turns curves of previously assembled good connections
and
the reference curves may be the maximum (reference curve 1) and minimum
(reference curve 2) curves of the previously assembled good connections. The
database may include curves from laboratory assembled connections and/or field
assembled connections.
[0041] Alternatively, the reference curves may be constructed by averaging
data of
the previously assembled good connections to create an average reference curve
(not shown). The average reference curve may then be overlayed onto the torque-
turns plot or the first and second reference curves may be constructed using a
standard deviation of the average curve. Alternatively, the reference curves
may be
theoretically constructed and may or may not be empirically calibrated.
[0042] The graphical evaluator 250 may also partition the torque-turns
plot into
one or more regions using the database 242 and respective input values 228,
230,
such as a reference region, delta turns region, shoulder torque region, and a
final
torque region. During makeup and/or after termination of the connection, the
graphical evaluator 250 may compare the torque-turns curve and determine if
the
curve is within the reference region. If the torque-turns curve is within the
reference
region, the graphical evaluator 250 may fill the region with a favorable
color, such as
11
CA 02886984 2015-03-31
WO 2014/071056 PCT/US2013/067845
green (depicted with cross hatching). If the torque-turns curve exits the
reference
region, the graphical evaluator may fill the reference region with an
unfavorable color,
such as red (Figure 7A, depicted with cross hatching). The graphical evaluator
250
may also receive comparisons for the other regions from the connection
evaluator
252 and may fill the respective regions red or green based on the comparisons.
The
graphical evaluator 250 may then make a recommendation to the technician
either
accepting or rejecting the connection. The graphical evaluator 250 may display
the
recommendation as well as the reason(s) for rejection, if applicable. The
technician
may also easily comprehend the reason(s) for rejection based on the color
fills of the
respective regions.
[0043] The graphical evaluator 250 may also be operable to overlay the
shoulder
threshold 224 onto the torque gradient curve (Figure 4B) and to display a
delta
gradient region using the input values 223. The graphical evaluator 250 may
receive
a comparison for the delta gradient region from the connection evaluator 252
and may
fill the delta gradient red or green based on the comparison. The torque
gradient
curve may be displayed in alignment (based on turns) with the torque-turns
curve.
Alternatively, the torque gradient curve may be inverted and share the turns
axis with
the torque-turns curve.
[0044] Once the connection 1 has been accepted, the torque-turns curve
may or
may not be added to the database 242.
[0045] Figures 5A and 5B illustrate operation of the graphical evaluator
250 for an
unacceptable connection 1 due to violation of a final torque criterion. The
graphical
evaluator 250 may receive an alert from the connection evaluator 252 that the
maximum final torque has been exceeded, fill the final torque region red, and
reject
the connection 1 with explanation. The graphical evaluator 250 may fill the
reference
region, the shoulder torque region, the delta turn region, and the delta
gradient region
green based on its own comparisons and those from the connection evaluator
252.
[0046] Figures 6A and 6B illustrate operation of the graphical evaluator
250 for an
unacceptable connection 1 due to violation of a delta turn criterion. The
graphical
evaluator 250 may receive an alert from the connection evaluator 252 that the
maximum delta turns value has been exceeded, fill the delta turn region red,
and
reject the connection 1 with explanation. The graphical evaluator 250 may fill
the
12
CA 02886984 2015-03-31
WO 2014/071056 PCT/US2013/067845
reference region, the shoulder torque region, the final torque region, and
delta
gradient region green based on its own comparisons and those from the
connection
evaluator 252.
[0047] Figures 7A and 7B illustrate operation of the graphical evaluator
250 for an
unacceptable connection 1 due to violation of a reference curve criterion. The
graphical evaluator 250 may determine that the torque-turns curve has exited
(two
places) the reference region, fill the reference region red, and reject the
connection 1
with explanation. The graphical evaluator 250 may fill the delta turn region,
the
shoulder torque region, the final torque region, and the delta gradient region
green
based on its own comparisons and those from the connection evaluator 252.
[0048] Figures 8A and 8B illustrate operation of the graphical evaluator
250 for an
unacceptable connection 1 due to violation of a delta gradient criterion. The
graphical
evaluator 250 may receive an alert from the connection evaluator 252 that the
minimum delta gradient was not reached, fill the delta gradient region red,
and reject
the connection 1 with explanation. The graphical evaluator 250 may fill the
reference
region, the shoulder torque region, the final torque region, and delta turn
region green
based on its own comparisons and those from the connection evaluator 252.
[0049] As discussed above, the delta gradients 223 may be input
separately from
the reference curve database 242, thereby providing independent criteria for
evaluating the connection. Alternatively, the delta gradients may be derived
from the
reference curve database 242 which may result in the criteria being dependent
or
independent depending on how the delta gradients are derived from the
database.
[0050] Additionally, the graphical evaluator 250 may include a menu of
options for
the technician to configure the reference curves.
[0051] Additionally, the control system 206 may include a storage device
221,
such as a hard drive or solid state drive, for recording the makeup data. The
stored
data may then be used to generate a post makeup report. Additionally, the
graphical
evaluator 250 may include a comments field for allowing the technician to
enter notes
for each individual connection and the notes may be recorded on the storage
device
221 for inclusion in the report. Additionally, the technician may accept or
reject the
connection according to or in spite of the graphical evaluator's
recommendation and
13
CA 02886984 2015-03-31
WO 2014/071056 PCT/US2013/067845
the technician may enter an explanation for the acceptance or rejection in the
comments field. Additionally, the graphical evaluator 250 may alert the
technician of
any detected anomalies in real time during the makeup using the alarm, such as
by
an audio alert and/or graphical alert.
[0052] Additionally, the graphical evaluator 250 may have the capability to
plot
selected connection graphs simultaneously ¨ for example to spot trends in make-
up
performance which might be attributable to changes occurring in the machinery
of the
tongs (component wear, slow hydraulic leak, changes in temperature affecting
hydraulics, etc.) or drift of the performance of the various sensors.
[0053] Alternatively, the tubular makeup system power drive may be a top
drive
instead of the tong assembly.
[0054] While the foregoing is directed to embodiments of the present
disclosure,
other and further embodiments of the disclosure may be devised without
departing
from the basic scope thereof, and the scope of the invention is determined by
the
claims that follow.
14
